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WHITE DELI SUB PRODUCTION PROCESS IMPROVEMENT. SOLUTION APPROACH May 21 st 2012. BACKGROUND. PROS Wonderful Product Good Quality Best Selling Good Production. CURRENT OBSERVATION Low DoS (Missing Quality) ! Remix Type and Rate Mixing Pace Breakdown s . SUPPORTING DATA.

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white deli sub production process improvement

WHITE DELI SUB PRODUCTION PROCESS IMPROVEMENT

SOLUTION APPROACH

May 21st 2012

background
BACKGROUND

PROS

  • Wonderful Product
  • Good Quality
  • Best Selling
  • Good Production
  • CURRENT OBSERVATION
  • Low DoS (Missing Quality) !
  • Remix Type and Rate
  • Mixing Pace
  • Breakdowns
supporting data
SUPPORTING DATA
  • Average Mixing Pace : 14mn30sec vs11mn37sec (Divider Time)
  • AverageQ1-2012 DoS11vs14 (Required for best quality)
  • Average remix rate 4.65%
  • 20% over 10% Dough Weight
  • Average Scrap rate 0.95%
  • Average Moline Line Impact 2.00%
  • Average Scaling Time 4mn
  • Average Loading Time 1mn
solution flow
SOLUTION FLOW

Implementing work sequence

  • Process flow plan:

work sequence and timing

  • Standard Work Diagram:

walking path

  • Job Aid :

training and reference

process flow plan
Process Flow Plan
  • Ingredients Scaling
  • Ingredient Loading
  • Auto-Delivery and Mixer Starting
  • Picking up remix
  • Mixing process
  • Unloading Mixer
  • Dividing Time
  • Idle Time
snapshot audit
Snapshot Audit
  • Using Mixer timers as reference
  • Link key process steps to timers reading
  • Read timer to assess pace keeping
  • Get back on pace after every unplanned gap
remix policy
Remix Policy
  • Providing new Remix buckets (max weight 53lb)
  • Put additional doubles into trash
  • No remix at Divider
  • Weight and record trash at the end of every session
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